Laser level

ABSTRACT

A laser level including a control mechanism housing which houses a control mechanism, the control mechanism including at least a top surface and a bottom surface. A protective structure extends from the control mechanism housing configured to protect the control mechanism from impact and including an upper structure which extends from a top surface of the control mechanism housing and a lower structure which extends from a bottom surface of the control mechanism housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/240,720, filed on Oct. 13, 2015. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to laser levels, particularly laser levelswith a protective structure.

BACKGROUND

There are various existing laser levels. It is desired to provide alaser level with an improved protective structure.

SUMMARY

According to an exemplary embodiment, there is a laser level. The laserlevel includes a control mechanism housing which houses a controlmechanism. A protective structure extends from the control mechanismhousing and is configured to protect the control mechanism from impact.

The laser level may include a laser projector.

The control mechanism housing may include a top surface and wherein thelaser projector is disposed at the top surface of the control mechanismhousing.

The protective structure may include an upper structure which extendsfrom the top surface of the control mechanism housing and extends beyondthe laser projector.

The upper structure may extend both upwardly and outwardly from the topsurface of the control mechanism housing.

The upper structure comprises an upper portion and a plurality of legsprojecting from the control mechanism housing to the upper portion.

The control mechanism housing is cube shaped and the legs are disposedat corners of the top surface of the control mechanism housing.

A top surface of the upper structure may have a substantially squareshape.

A top surface of the upper structure may be a closed shape.

The top surface of the upper structure may be open inside the closedshape.

The control mechanism housing may include a bottom surface opposite thetop surface.

The protective structure may be made of a shock absorbing material.

The shock absorbing material may include at least one of rubber, foamand a shock absorbing plastic.

The control mechanism may include at least one laser.

The control mechanism may include a motor.

The control mechanism may include at least one lens.

The protective structure may further include a lower structure whichextends from a bottom surface of the control mechanism housing.

The lower structure may extend both downwardly and outwardly from thetop surface of the control mechanism housing.

The lower structure may include a lower portion and a plurality of lowerlegs projecting from the control mechanism housing to the lower portion.

The control mechanism housing may be cube shaped and the lower legs maybe disposed at corners of the bottom surface of the control mechanismhousing. A bottom surface of the lower structure may have asubstantially square shape.

A bottom surface of the lower structure may be a closed shape.

The bottom surface of the lower structure may be open inside the closedshape.

The laser level may further include a battery to power the laser level.

The battery may be a removable battery pack.

The removable battery pack may be configured to power a variety of powertools and other products including such products as a drill, saw,sander, radio, infrared detector, lawn mower, string trimmer.

The laser level may be configured such that when placed on a flatsurface, only the protective structure contacts the flat surfaceregardless of the orientation of the laser level.

The laser level may be configured such that it can be stably positionedon a flat surface in at least six orientations.

The at least six orientations may correspond to the six sides of thecontrol mechanism housing.

There may be spaces between the control mechanism housing and theflanges.

The flanges may be usable as handles.

The upper protective structure may be made of rubber.

The legs of the upper protective structure may be made of rubber with afirst durometer and the flanges of the upper protective structure may bemade of a rubber with a second durometer, different than the firstdurometer.

The first durometer may be higher than the first durometer.

The second durometer may be lower than the first durometer.

According to another exemplary embodiment, the flanges of the upperprotective structure may be made of rubber and the legs of the upperprotective structure may be made or a material other than rubber. Thematerial other than rubber may be metal. The metal may be spring steel.

The control mechanism housing may be made of a rigid material. The rigidmaterial may be acrylonitrile butadiene styrene (ABS). The rigidmaterial may be high impact polypropylene. The rigid material may behigh impact polystyrene.

According to another exemplary embodiment, the flanges could form agenerally elliptical shape and the control mechanism housing could be agenerally elliptical cylinder.

According to another exemplary embodiment, the flanges of the protectivestructure can form a triangular shape and the control mechanism housingcan be a generally triangular prism shape. In other embodiments, theflanges could form a shape with five sides, six sides, seven sides,eight sides or more and the control mechanism housing can be shaped witha corresponding structure. In other embodiments, the shape formed by theflanges and the control mechanism housing may not correspond. Forexample, the flanges may form a hexagon shape while the controlmechanism housing is generally cube shaped.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an exemplary embodiment of alaser level;

FIG. 2 is another perspective view of the exemplary embodiment of thelaser level;

FIG. 3 is a top view of the exemplary embodiment of the laser level;

FIG. 4 is a back view of the exemplary embodiment of the laser levelshowing the attached battery pack;

FIG. 5 is a left side view of the exemplary embodiment of the laserlevel;

FIG. 6 is a right side view of the exemplary embodiment of the laserlevel;

FIG. 7 is a front view of the exemplary embodiment of the laser level;

FIG. 8 is a bottom view of the exemplary embodiment of the laser level;

FIG. 9 is perspective view of the exemplary embodiment of the laserlevel with the battery pack removed;

FIG. 10 is a top view of the exemplary embodiment of the laser levelwith the battery pack removed;

FIG. 11 is a back view of the exemplary embodiment of the laser levelshowing the battery pack connection section with the battery packremoved;

FIG. 12 is a left side view of the exemplary embodiment of the laserlevel with the battery pack removed;

FIG. 13 is a right side view of the exemplary embodiment of the laserlevel with the battery pack removed;

FIG. 14 is a front view of the exemplary embodiment of the laser levelwith the battery pack removed;

FIG. 15 is a bottom view of the exemplary embodiment of the laser levelwith the battery pack removed;

FIG. 16 is an illustration of a laser level according to a secondexemplary embodiment;

FIG. 17 is an illustration of a laser level according to a thirdexemplary embodiment;

FIG. 18A is a simplified electrical schematic according to an exemplaryembodiment; and

FIG. 18B is a simplified schematic according to an exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

An exemplary embodiment according to the present application is shown inFIGS. 1-15. As shown in FIG. 1, the exemplary embodiment shows a rotarylaser level 10 with a protective s. Rotary laser levels are known, forexample, as shown in U.S. Pat. Nos. 4,854,703; 4,751,782; and 6,338,681,which are herein incorporated by reference in their entirety. Anotherrotary laser level is shown in US Patent Application Publication No.2014/0203172, which is hereby incorporated by reference. The presentapplication may also be applicable to other types of lasers such as U.S.Pat. Nos. 7,665,217; 7,076,880; 6,964,106; 7,481,002; 7,027,480;8,640,350; 6,606,798; 7,013,571; 7,111,406; 7,296,360; and 7,571,546,which are herein incorporated by reference in their entirety.

FIGS. 1-8 illustrate the exemplary embodiment of the invention with theremovable battery pack 200 attached. FIGS. 9-15 illustrate the exemplaryembodiment of the invention without the battery pack.

As shown in the Figs., there is a laser level 10. The laser level 10includes a control mechanism housing 20. A laser projector 30 extendsfrom the control mechanism housing and is configured to project a laseronto a surface. In the case of the rotary laser shown, the laserprojection can be a 360 degree rotary projection. In other instances,the projector 30 may project one or more dot, one or more lines or acombination of lines and dots.

The control mechanism housing 20 includes a control mechanism whichprovides for projection of one or more laser beams or dots by the laserprojector 30. The control mechanism may include, among other things; anLED or other light source; one or more lenses; one or more mirrors; amotor; and a microprocessor configured to control the laser level 10.The control mechanism may be a control mechanism shown in one of U.S.Pat. No. 4,854,703; U.S. Pat. No. 4,751,782; U.S. Pat. No. 6,338,681; US2014/0203172; U.S. Pat. No. 7,665,217; U.S. Pat. No. 7,076,880; U.S.Pat. No. 6,964,106; U.S. Pat. No. 7,481,002; U.S. Pat. No. 7,027,480;U.S. Pat. No. 8,640,350; U.S. Pat. No. 6,606,798; U.S. Pat. No.7,013,571; U.S. Pat. No. 7,111,406; U.S. Pat. No. 7,296,360; and U.S.Pat. No. 7,571,546 all of which have been incorporated by reference. Forexample, the control mechanism housing 20 may include the controlmechanism housed in the upper casing part shown and described U.S. Pat.No. 4,854,703. Alternatively, the control mechanism housing 20 mayinclude the control mechanism shown and described U.S. Pat. No.8,640,350. In various embodiments, the projector 30 may be disposed atdifferent places along the control mechanism housing 20. For example,the projector 30 may be on a front surface or may be internal to thecontrol mechanism housing 20 with beams projecting out from the controlmechanism housing 20.

The control mechanism housing 20 has a substantially cubical shape.Accordingly, it has a top surface 21, a bottom surface 22, a leftsurface 23, a right surface 24, a front surface 25 and a back surface26. The removable battery pack 200 is provided at the back surface. Theremovable battery pack 200 provides power for the laser level 10. Theremovable battery pack 200 may be a power tool battery pack such that itcan be removed and mounted to a variety of power tools, outdoor powertools, cleaning tools, or other tools or products. As shown in FIG. 11,the laser level 10 includes a receptacle 201 for receiving the batterypack. The receptacle 201 can be one of many known designs for receivinga battery pack, including those for receiving a power tool battery pack.The control mechanism housing 20 may be made of a rigid material such asAcrylonitrile butadiene styrene (ABS), high impact polypropylene or highimpact polystyrene (HIPS). In an embodiment, the control mechanismhousing 20 may be made of a material having a Rockwell R hardness of 60to 140. In other embodiments, the control mechanism housing may be madeof a material having a Rockwell R hardness of 70 to 130, 80 to 120 or 80to 114.

As shown in FIGS. 1-15, the laser level 10 has a protective structure50. The protective structure 50 comprises an upper protective structure100 and a lower protective structure 150. The upper protective structure100 projects upwardly and outwardly from the top surface 21 and thelower protective structure 150 projects downwardly and outwardly fromthe bottom surface 22. The protective structure 50 in the exemplaryembodiment is made of a shock absorbing material which can deform onimpact at a controlled rate to dissipate the impact energy over a longerperiod. In the exemplary embodiment, the material of the protectivestructure 50 is designed to absorb shocks better than the material ofthe control mechanism housing 20. The shock absorbing material may be amaterial such as rubber, foam or a shock absorbing plastic. As can beappreciated, because the protective structure extends beyond the controlmechanism housing 20, it protects the control mechanism housing 20 fromimpact when dropped from a variety of orientations. The flanges and thelegs may be made of different durometers of rubber. For example, therubber used for one or more legs may have a higher durometer than therubber used for one or more flange. The rubber used for one or moreflange may have a higher durometer than one or more legs.

In other exemplary embodiments, it is contemplated that the legs may bemade from metal, such as spring steel, for example. In other exemplaryembodiments, the protective structure may comprise a molded skeletonmade from an impact resistant polymer that is overmolded in rubber orfoamed rubber.

The upper protective structure 100 has four flanges 101, 102, 103, and104. The flanges run roughly parallel to upper edges of the controlmechanism housing 20. The flanges 101, 102, 103 and 104 are connected tothe control mechanism housing 20 by upper legs 110. The lower protectivestructure 150 has four flanges 151, 152, 153, and 154. The flanges runroughly parallel to upper edges of the control mechanism housing 20. Theflanges 151, 152, 153 and 154 are connected to the control mechanismhousing 20 by lower legs 160.

In the exemplary embodiment, each upper corner includes a pair of legs110 and each lower corner includes a pair of legs 160. In otherembodiments, there may be additional or fewer legs. For example, eachcorner may include only one leg. The legs can also be dimensioneddifferently. For example, they could be made thinner or thicker thanshown in the exemplary embodiment. In the exemplary embodiment, the legs110, 160 are made of the same material as the flanges 101, 102, 103,104, 151, 152, 153, and 154. In other embodiments, the legs 110, 160 maybe made of a different material than the flanges. The legs 110, 160 maybe the same or differ in various ways.

The upper protective structure 100 is configured so that the flanges101, 102, 103 and 104 rise above the projector 30. In this way, theprojector 30 is particularly protected against impact and the flanges101, 102, 103 and 104 do not block lasers projecting from the projector30. In the shown exemplary embodiment, the upper legs 110 are longerthan the lower legs 160. This allows the upper legs 110 to providesufficient clearance for the projector 30 so that the flanges 101, 102,103 and 104 do not block any projection from the projector 30.

The legs creates spaces 111, 112, 113, 114, 161, 162, 163 and 163between the control mechanism housing 20 and the flanges 101, 102, 103,104, 151, 152, 153, and 154. The spaces allow for a decreased weight.Additionally, providing this spaced construction provides better impactprotection. Also, as can be appreciated, the flanges 101, 102, 103, 104,151, 152, 153, and 154 can serve as grab handles so the laser level tool10 can be carried or re-positioned. Additionally, the flanges 101, 102,103, 104, 151, 152, 153, and 154 have at least one set of aligned flatswhich allows the laser level 10 to be accurately re-positioned on itsside to project a vertical beam. That is, when sitting upright, thelaser level 10 projects a tool in a horizontal plane. The flats allowthe laser level 10 to be placed on its sides so that a beam can beprojected vertically. The flanges are also designed so as to notinterfere with mounting of the tool on a tripod either vertically orhorizontally. In the exemplary embodiment, the laser level 10 can bestably positions on a flat surface in at least six orientations. The atleast six orientations correspond to the six sides of the cube-shapedcontrol mechanism housing 20. That is, the laser level 10 can bepositioned on a flat surface upright, upside-down or on any of its foursides. In any of these orientations, the laser level 10 will sit stablywith only the protective structure 50 resting on the flat surface.

As shown in, for example, FIG. 3, the upper flanges 101, 102, 103, 104form a closed shape that is generally square. The structure is openinside the closed square shape, allowing access to the laser projector30. Similarly, as is shown in FIG. 8, the lower flanges 151, 152, 153,154 form a closed shape that is generally square shape. The structure isopen inside the closed square shape, allowing access to the bottomsurface 22 of the control mechanism housing 20.

FIG. 16 shows another exemplary embodiment of a laser level 210. Unlessotherwise stated, the features of this exemplary embodiment are the sameas in the previous exemplary embodiment. For example, similar materialscan be used in this exemplary embodiment and similar laser mechanismsare also possible. In this instance, the laser projector 230 is disposedat a center of a control mechanism housing 220. There is a protectivestructure 250 which includes an upper protective structure 300 and alower protective structure 350. The upper protective structure 300includes flanges 301, 302, 303, 304 which provide a generally squareshape. The lower protective structure 350 includes flanges 351, 352 (andtwo other flanges not shown) which also provide a generally squareshape. In this exemplary embodiment, the upper legs 310 include a singleleg 310 at each corner of the control mechanism housing 220. As can beappreciated, in this embodiment, laser beams projected by the projector230 do not have to pass through the upper legs 310. Accordingly, theupper legs 310 can be made thicker without impeding the projection of alaser beam. In this exemplary embodiment, the lower legs 360 alsocomprise a single leg 360 at each corner.

As shown in FIG. 16, this exemplary embodiment includes support posts240. The support posts 240 connect portions of the control mechanismhousing 220. As can be appreciated, laser beams projected from the laserprojector 230 may pass through this section of the housing 220.Accordingly, having relatively thin supports posts 240 lessens theamount of any disruption of a laser beam.

Another exemplary embodiment of a laser level is shown in FIG. 17. Asshown in FIG. 17, the laser level 410 of this exemplary embodiment isgenerally cylindrically shaped. In particular, the control mechanismhousing 420 is roughly cylindrical shaped and the overall laser level410 is roughly cylindrically shaped. As shown in FIG. 17, the projector430 in this embodiment is at a top end of the housing 420.

As with the previous embodiments, the laser level 410 of FIG. 17 has aprotective structure 450 consisting of an upper protective structure 500and a lower protective structure 550. The upper protective structure 500includes a generally circular flange 501 which is supported by fourupper legs 510. The flange 510 includes a series of bumpers 511. In theexemplary embodiment, there are four bumpers 511 which are disposed ateach of the legs 510. In other embodiments, there may be a greaternumber of bumpers 511 or fewer bumpers 511.

The lower protective structure 550 likewise includes a generallycircular flange 551 which is supported by four lower legs 560. The lowerprotective structure 550 also includes a series of bumpers 561. Thebumpers 511, 561 make it so that if the laser level 410 is placed on itsside on a flat surface, the protective structure 450 contacts the flatsurface and the control mechanism housing 420 does not. In thisexemplary embodiment, because of the shape of the laser level 410, thelaser level 410 can be rolled when on its side if pushed by a user. Aswith other embodiments, it can also be placed upside down. The bumpers511, 561 also allow it to rest on each of its sides as each bumper willresist further rolling.

In other embodiments, the shape of the laser level could be different.For example, in

FIG. 17, the flanges 501, 551 are generally circular and the controlmechanism housing 420 is generally cylindrical. The shape could bemodified so that the flanges are generally elliptical and the controlmechanism housing is a generally elliptical cylinder. The major axis ofthe elliptical shape can be different in different embodiments.

Simplified schematics for operation of a laser level are shown in FIGS.18A and 1813. As shown in FIG. 18A, battery pack 200 provides power to alight source 201, a controller 202 and motor 203. The light source 201may be, for example, a laser diode. The controller 202 may, for example,a microcontroller or microprocessor. As shown in FIG. 18B, there is alight source 201. The light source 201 projects light through acollimator lens 204 and the light then travels through a prism 205 andfinally is reflected off of mirror 206 disposed in the projector 30.Motor 203 rotates the projector 30. Alternatively, the motor 203 mayrotate the mirror 206 directly. As previously discussed other mechanismsfor the laser are possible and part of the present application.

In an exemplary embodiment, the upper protective structure 100 may bemade of a material having a Shore A hardness of 40 to 100; 50 to 100; 60to 100; 70 to 100; 70 to 90; 60 to 90; 50 to 90; 40 to 90 or 40 to 80.

In an exemplary embodiment, the lower protective structure may be madeof a material having a Shore A hardness of 40 to 100; 50 to 100; 60 to100; 70 to 100; 70 to 90; 60 to 90; 50 to 90; 40 to 90 or 40 to 80.

In an exemplary embodiment, the flanges of the upper protectivestructure may be made of a material having a Shore A hardness of 40 to100; 50 to 100; 60 to 100; 70 to 100; 70 to 90; 60 to 90; 50 to 90; 40to 90 or 40 to 80.

In an exemplary embodiment, the flanges of the lower protectivestructure may be made of a material having a Shore A hardness of 40 to100; 50 to 100; 60 to 100; 70 to 100; 70 to 90; 60 to 90; 50 to 90; 40to 90 or 40 to 80.

The legs of the upper protective structure may be made of a materialhaving a higher hardness than the material of the flanges of the upperprotective structure. The legs of the upper protective structure may bemade of a material having a lower hardness than the material of theflanges of the upper protective structure.

The legs of the lower protective structure may be made of a materialhaving a higher hardness than the material of the flanges of the lowerprotective structure. The legs of the lower protective structure may bemade of a material having a lower hardness than the material of theflanges of the lower protective structure.

In another embodiment, the flanges of the protective structure can forma triangular shape and the control mechanism housing can be generallyshaped as a triangular prism. In other embodiments, the flanges couldform a shape with more sides such as 5 sides (pentagon), six sides(hexagon), seven sides (heptagon), eight sides (octagon), etc. and thecontrol mechanism housing can be shaped with a corresponding structure(i.e., having a cross-section that corresponds to the shape formed bythe flanges).

In other embodiments, the shape formed by the flanges and the controlmechanism housing may not correspond. For example, the flanges may forma hexagon shape while the control mechanism housing is generally cubeshaped.

Various different features have been shown and described with respect todifferent embodiments. It is contemplated that the features of theembodiments could be combined or used in other embodiments. For example,a centrally located projector as shown in FIG. 16 could also be usedwith a cylindrically laser level of the type shown in FIG. 17.

While the invention has been described by way of exemplary embodiments,it is understood that the words which have been used herein are words ofdescription, rather than words of limitation. Changes may be made withinthe purview of the appended claims, without departing from the scope andspirit of the invention in its broader aspects.

What is claimed is:
 1. A laser level, comprising: a control mechanismhousing which houses a control mechanism, the control mechanismincluding at least a top surface and a bottom surface; a protectivestructure extending from the control mechanism housing configured toprotect the control mechanism from impact and including an upperstructure which extends from a top surface of the control mechanismhousing and a lower structure which extends from a bottom surface of thecontrol mechanism housing.
 2. The laser level of claim 1, wherein thelower structure extends both downwardly and outwardly from the bottomsurface of the control mechanism housing.
 3. The laser level of claim 2,wherein the upper structure extends both upwardly and outwardly from thetop surface of the control mechanism housing.
 4. The laser level ofclaim 3, further comprising a laser projector.
 5. The laser level ofclaim 4, wherein the laser projector is disposed at the top surface ofthe control mechanism housing.
 6. The laser level of claim 5, whereinthe upper structure extends beyond the laser projector
 7. The laserlevel of claim 1, wherein the upper structure comprises an upper portionand a plurality of legs projecting from the control mechanism housing tothe upper portion.
 8. The laser level of claim 7, wherein the controlmechanism housing is generally cube shaped and the legs are disposed atcorners of the top surface of the control mechanism housing.
 9. Thelaser level of claim 1, wherein a top surface of the upper structure hasa substantially square shape.
 10. The laser level of claim 1, wherein atop surface of the upper structure is a closed shape.
 11. The laserlevel of claim 10, wherein the top surface of the upper structure isopen inside the closed shape.
 12. The laser level of claim 1, whereinthe protective structure is made of a shock absorbing material.
 13. Thelaser level of claim 12, wherein the shock absorbing material comprisesat least one of rubber, foam or plastic.
 14. The laser level of claim13, wherein the control mechanism comprises at least one laser and atleast one lens.
 15. The laser level of claim 1, wherein the lowerstructure comprises a lower portion and a plurality of lower legsprojecting from the control mechanism housing to the lower portion. 16.The laser level of claim 1, wherein the laser level is configured suchthat when placed on a flat surface, only the protective structurecontacts the flat surface regardless of the orientation of the laserlevel.
 17. The laser level of claim 1, wherein the laser level isconfigured such that it can be stably positioned on a flat surface in atleast six orientations.
 18. The laser level of claim 17, wherein thecontrol mechanism housing is generally cube-shaped and includes sixsides; and wherein the at least six orientations correspond to the sixsides of the control mechanism housing.
 19. A laser level, comprising: acontrol mechanism housing which houses a control mechanism, the controlmechanism including at least a top surface and a bottom surface; aprotective structure extending from the control mechanism housingconfigured to protect the control mechanism from impact and including anupper structure which extends from the top surface of the controlmechanism housing and a lower structure which extends from the bottomsurface of the control mechanism housing; wherein the lower structureextends both downwardly and outwardly from the bottom surface of thecontrol mechanism housing; wherein the upper structure extends bothupwardly and outwardly from the top surface of the control mechanismhousing; and wherein the laser level is configured such that when placedon a flat surface, only the protective structure contacts the flatsurface regardless of the orientation of the laser level.
 20. A laserlevel, comprising: a control mechanism housing which houses a controlmechanism, the control mechanism including at least a top surface and abottom surface; a protective structure extending from the controlmechanism housing configured to protect the control mechanism fromimpact and including an upper structure which extends from the topsurface of the control mechanism housing and a lower structure whichextends from the bottom surface of the control mechanism housing;wherein the lower structure extends both downwardly and outwardly fromthe bottom surface of the control mechanism housing; wherein the upperstructure extends both upwardly and outwardly from the top surface ofthe control mechanism housing; and wherein the laser level is configuredsuch that it can be stably positioned on a flat surface in at least sixorientations, including a first orientation to project a horizontal beamand in a second orientation to project a vertical beam.